Electrically conductive composite material

ABSTRACT

An electrically conductive composite material includes metallic nanostrands distributed throughout a matrix constructed of a polymer, ceramic, or elastomer. The nanostrands may have an average diameter under four microns and an average aspect ratio over ten-to-one. Larger fibers may also be included to enhance electrical conductivity or other properties. The nanostrands and/or fibers may be magnetically oriented to enhance electrical conductivity along one direction. A pressure sensor may be formed by utilizing an elastomer for the matrix. Electrical conductivity through the composite material varies in proportion to deflection of the elastomer. A composite material may be applied to a surface as an electrically conductive paint. Composite materials may be made by cutting a blank of the nanostrands to the desired shape, inserting the matrix, and curing the matrix. Alternatively, a suspension agent may first be used to dispose powdered nanostrands in the desired shape.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/373,363 filed Apr. 17, 2002 and entitled METAL NANOSTRAND MATERIAL and U.S. Provisional Application No. 60/412,662 filed Sep. 20, 2002 and entitled NICKEL NANOSTRANDS, both of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to polymer, elastomer, or ceramic materials or composite materials employing polymers, elastomers, or ceramics as their matrix. More specifically, the present invention relates to the use of metallic nanostrands to form polymers, elastomers, ceramics, or composite materials with enhanced electrical conductivity.

2. Description of Related Art

Polymeric materials, either alone or reinforced with powders or fibers, are an attractive engineering material with respect to cost, weight, manufacturability and many other advantages. However, with the exception of some intrinsically conducting polymers, polymers generally possess poor electrical conductivity.

There are many conventional methods by which conductivity may be introduced into a polymer or composite system. One method is by coating the polymer with a conductive metal coating. A second method is the introduction of conductive additives such as metal or metal-coated powders or fibers into the polymer. Conventional additives include powders of metals such as silver, copper, nickel, iron and carbon, or fibers made of or coated with such metals. Another method is the creation of a conductive paint coating by adding metal powders or flakes to a paint, after which the paint may be used as a conductive coating.

In the case of composite materials, the reinforcing fibers may already be intrinsically conductive, such as is the case of carbon or metal-coated fibers. However, in the case of such composites, the conductivity is limited to the direction of the fibers. The adhesive polymer matrix of the composite insulates the fibers and greatly inhibits current flow in directions nonparallel to the fibers.

The poor electrical conductivity of such composite materials limits their usefulness in applications such as electromagnetic shielding, circuits, antennas, and the like. Furthermore, there are many applications in which known polymer-based composites may not be suitable because they do not sufficiently possess properties such as mechanical strength, thermal insulation, stiffness, and hardness. Known polymer-based composites may not be well suited to applications in which large, constant and/or repeated deflections occur, or applications in which deflection is to be measured.

Moreover, there are many applications in which it is desirable to coat an object with a conductive coating. It would be advantageous to enhance the electrical conductivity of such coatings for potential high-current applications such as electromagnetic shielding. Yet further, many applications require the use of objects with relatively complex shapes. Such complex shapes can be difficult or impossible to form from composite materials having the desired electrical conductivity.

Accordingly, it would be an advancement in the art to provide composite materials having increased thermal conductivity in comparison with the prior art. Furthermore, it would be an advancement in the art to provide conductive composite materials having a variety of additional characteristics such as mechanical strength, thermal insulation, stiffness, and hardness. Additionally, it would be an advancement in the art to provide conductive composite materials suitable for large deflection applications, and especially for deflection measurement. It would also be an advancement in the art to provide composite materials capable of being applied as highly conductive coatings. Yet further, it would be an advancement in the art to provide methods by which relatively complex, conductive composite shapes may be relatively easily and inexpensively manufactured.

SUMMARY OF THE INVENTION

The apparatus of the present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available conductive materials. Thus, it is an overall objective of the present invention to provide conductive composite materials and associated manufacturing methods that remedy the shortcomings of the prior art.

U.S. Pat. No. 5,130,204, which is incorporated herein by reference, claims and discloses a method of manufacturing metal fibers, and mentions the combination of such fibers with a polymer to create an electrically conductive composite. An objective of this patent is to further demonstrate the multiple unique properties of this material as a conductive additive to polymers and ceramics, both singularly and as a co-additive to composite materials.

To achieve the foregoing objective, and in accordance with the invention as embodied and broadly described herein in one embodiment, a composite material may have a matrix formed of a nonmetallic material, which may comprise a polymer, a ceramic, an elastomer, or any combination thereof. Metallic nanostrands are distributed throughout the matrix. The metallic nanostrands may have an average diameter under about four microns and an average aspect ratio (length-to-diameter ratio) of about ten-to-one or greater. The metallic nanostrands may be constructed of a metal such as nickel or iron. The nanostrands may also provide additional mechanical strength and/or thermal conductivity.

The metallic nanostrands may have a random orientation so that the electrical conductivity of the composite material is substantially the same in all directions. The metallic nanostrands cross each other to provide many current pathways. If desired, nanostrands with a comparatively high degree of branching may be used to enhance the electrical conductivity of the composite material.

According to one exemplary manufacturing method, such a composite material may be formed by mixing the nanostrands, in powder form, into a resin or other flowable or powdered form of the matrix. The resin or other flowable or powdered material may then be allowed to cure or set or cool (as in thermoplastics) to form the composite material. Depending on the type of material used to form the matrix, baking or other steps may additionally or alternatively be applied to obtain the composite material.

According to one alternative embodiment, fibers constructed of an electrically conductive material may be added to the matrix and the nanostrands of the previously described composite material. The fibers may be formed of carbon, nickel-coated carbon, or the like. The fibers may be chopped fibers or continuous fibers, depending on the type of composite to be produced.

The fibers cooperate with the nanostrands to synergistically enhance the electrical conductivity of the resulting composite material. Thus, a lower concentration of the nanostrands and fibers, combined, may be required to obtain a given level of electrical conductivity than would be required using just the fibers or the nanostrands, alone. The fibers may also or alternatively be selected to independently provide additional properties, such as mechanical strength, stiffness, thermal conductivity, and the like. Thus, design of the composite material for electrical conductivity may optionally be decoupled from design for such other properties.

According to another alternative embodiment, a composite material may be formed by exposing either of the previously described composite materials to magnetic flux. For example, the composite material of the immediately preceding embodiment may be disposed adjacent to a permanent magnet or an electromagnet in such a manner that magnetic flux passes through the composite material in a longitudinal direction. The magnetic flux operates to orient the nanostrands and the fibers in a direction generally parallel to the flux.

The magnetic flux may be applied prior to curing or other hardening of the matrix material, if desired. After magnetic orientation of the fibers and nanostrands, the matrix may be cured to fix the nanostrands and fibers in a substantially parallel orientation. The result is the enhancement of electrical conductivity in the direction of the magnetic flux.

According to another embodiment, the nanostrands may be included, with or without the fibers, in a matrix formed of an elastomeric material. It has been discovered that, when disposed in an elastomer, the nanostrands tend to provide an electrical conductivity that increases in proportion to tensile or compressive strain. Thus, the deformation of the resulting composite material may easily be measured by using an electric circuit with a voltage source and a current sensor or the like to measure the electrical conductivity of the composite material. Such a composite material may be disposed in a pressure sensor, accelerometer, or the like.

If desired, the matrix may be a material with a high coefficient of thermal expansion. A high coefficient of thermal expansion may facilitate use of the composite material to measure temperature by measuring the deformation of the composite material in the manner indicated above.

According to another alternative embodiment, an electrically conductive mixture may be formed by mixing metallic nanostrands (with or without chopped fibers) with a matrix that can be applied to a surface in a relatively flowable form. The matrix may be a polymer such as those typically used for paints. The electrically conductive mixture may then be applied to a surface of a body. The mixture may be applied mechanically, for example, through the use of a brush, roller or sprayer.

The electrically conductive mixture may then be permitted to dry or cure. The surface of the body is thus made conductive. If desired, the entire body may be coated with the electrically conductive mixture in a similar manner, so that the body behaves electrically in a manner similar to that of a solid conductor.

According to one method of manufacture, a composite material may be made by, first, forming a porous sponge (i.e., a brick or other standard shaped porous mesh) of the metallic nanostrands as the nanostrands are manufactured. The porous sponge may be called a “blank.” A portion of the blank may then be mechanically cut, laser cut, compressed or otherwise removed or deformed to provide a nanostrand preform having a desired shape. Such performs are typically over 95% porous, and uniquely often over 99% porous. The matrix material is then inserted into the preform, for example, in the viscous phase, monomer phase or vapor phase. The matrix material may then be cured, set, or cooled to solidify the matrix with the nanostrands embedded therein. The resulting piece composite material has the desired shape, which may be directly adapted or further shaped to suit a particular application.

According to another method of manufacture, the nanostrands may first be formed as a powder, for example, by manufacturing a porous sponge of nanostrands and then breaking up the sponge to provide the powder. A suspension agent in a liquid mixture is then directed into the nanostrands. The suspended powdered nanostrands may then be disposed in the desired shape, for example, by inserting them into a mold. The suspension agent causes the nanostrands to adhere to one another, while the large length and small diameter of the self supporting nanostrands causes the material to remain highly porous. The bulk of the suspension agent is subsequently removed via evaporation, solvation, or the like, but a small surface quantity remains, so that the nanostrands adhere to each other and are porous like the preform described in connection with the previous method.

The matrix material is then directed into the nanostrands in a manner similar to that described previously. The matrix material is cured, set, or cooled to form the composite material with the desired shape. This method may be used to enable composite materials to be manufactured from powdered nanostrands efficiently shipped in bulk.

Through the use of the conductive composite materials and methods of the present invention, conductive polymers, elastomers, ceramics, or composite materials having enhanced electrical conduction and/or other properties may be made. Such composite materials may be easily formed in a wide variety of shapes. These and other features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the manner in which the above-recited and other features and advantages of the invention are obtained will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a perspective view of an article formed of a composite material according to one embodiment of the invention, with an inset illustrating the nanostrands and the matrix of the composite material;

FIG. 2 is a perspective view of an article formed of a composite material according to one alternative embodiment of the invention, with an inset illustrating fibers included along with nanostrands and a matrix;

FIG. 3 is a side elevation, perspective view of a composite material according to another alternative embodiment of the invention, shown adjacent to a magnet used to magnetically align nanostrands and fibers within a matrix as shown in the inset;

FIG. 4 is a perspective view of a pressure sensor incorporating a composite material according to another embodiment of the invention;

FIG. 5 is a perspective view of an article with a surface coated by an electrically conductive mixture according to the invention;

FIG. 6 is a flowchart diagram illustrating one method of forming a composite article with a desired shape; and

FIG. 7 is a flowchart diagram illustrating another method of forming a composite article with a desired shape.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The presently preferred embodiments of the present invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus, system, and method of the present invention, as represented in FIGS. 1 through 7, is not intended to limit the scope of the invention, as claimed, but is merely representative of presently preferred embodiments of the invention.

For this application, the phrases “connected to,” “coupled to,” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, and thermal interaction. The phrase “attached to” refers to a form of mechanical coupling that restricts relative translation or rotation between the attached objects.

Referring to FIG. 1, a perspective view illustrates an article 10 with an arbitrarily selected rectangular shape. Of course, the article 10 can be formed into other shapes, but the rectangular shape has been selected for ease of illustration. The article 10 has a longitudinal direction 12, a lateral direction 14, and a transverse direction 16. The article 10 is constructed of a composite material 20. The composite material 20 provides a relatively high degree of electrical conductivity to enable current flow through the article 10 with comparatively low resistance.

As shown by the inset, the composite material 20 has a nonmetallic matrix 22, or matrix 22, in which a plurality of metallic nanostrands 24 are distributed in a generally random orientation. The matrix 22 may be substantially formed of a nonmetallic material such as a polymer, ceramic, or elastomer. The matrix 22 may include various additives, or may be a combination of multiple materials. The following polymers have been tested and found to possess enhanced electrical conductivity when combined with metallic nanostrands: epoxy, acrylic, water based paints, urethanes, lacquers, silicone elastomers, and thermoplastics such as polyethylene. The matrix 22 is, however, not limited to these materials.

The metallic nanostrands 24, or nanostrands 24, are constructed of a metal such as nickel, iron, cobalt, chromium, molybdenum and other assorted metals. The metallic nanostrands 24 may be those disclosed in U.S. Pat. No. 5,130,204, which is incorporated herein by reference. Several examples in the aforementioned patent illustrate how the nanostrands 24 may be manufactured.

As shown, the nanostrands 24 have an average diameter 28 and an average length 30, indicated by the dimensions in the inset of FIG. 1. The average diameter and length 28, 30 are shown on only one of the nanostrands 24, but are nevertheless intended to represent average values. The nanostrands 24 also have an average aspect ratio, which may be defined as the average length 30 divided by the average diameter 28 (the length-to-diameter ratio).

The nanostrands typically exhibit diameters 28 as small as twenty-five nanometers and as large as several microns, depending on the conditions of manufacture and the desired application. The average diameter 28 may range from about one tenth of a micron (one hundred nanometers) to about four microns. More specifically, for certain applications, the average diameter 28 may range from about one-half micron to about two microns. In certain embodiments, the average diameter 28 may be about one micron, if desired. Proper selection of the average diameter 28 may enhance the electrical conductivity of the composite material 20.

These metal nanostrands typically exhibit aspect ratios of at least twenty-to-one, and often between about fifty-to-one and about five-hundred to one. In some cases, aspect ratios of several thousand to one have been observed. Use of longer aspect ratios may enhance the electrical conductivity of the composite material 20, but longer aspect ratios also introduce practical limitations with respect to incorporating the nanostrands into an article. Nanostrands with an aspect ratio over about one-thousand-to-one are often difficult to disperse. Thus, the average aspect ratio may advantageously range from about ten-to-one to about one-thousand-to-one.

The unique nanostrand manufacturing process referred to in U.S. Pat. No. 5,130,204 allows nanostrands to be manufactured to a desired diameter and aspect ratio. The aspect ratios are further limited primarily by the type of process used to form the article 10; some manufacturing processes may tend to sever the nanostrands, thereby reducing the aspect ratio. Articles may also be formed of “chopped fiber” nanostrands, i.e., nanostrands with a deliberately limited average length 30, and therefore a limited aspect ratio.

Electrical conductivity may be provided by using comparatively low volumetric concentrations of the nanostrands 24. The volumetric concentration of nanostrands 24 (i.e., volume of the nanostrands 24 divided by the volume of the composite material 20) may range from about one-half of a percent to about twenty percent. Further, the volumetric concentration may range from about three percent to about twelve percent. Some factors that affect the needed volumetric concentration are the average diameter 28, the average aspect ratio, the degree of branching present in the nanostrands 24, and the surface chemistry, surface tension, and viscosity of the nanostrands 24 and the matrix 22.

More precisely, a comparatively large aspect ratio may enhance the electrical conductivity of the composite material 20. Furthermore, a relatively high degree of branching of the nanostrands 24 is also helpful in providing high electrical conductivity. The branching may enhance the interconnection of the nanostrands 24, thereby providing more current pathways through the composite material 20. The degree of branching may be altered by changing the parameters used to form the nanostrands in the method of U.S. Pat. No. 5,130,204.

Electrical conductivity is also improved by adapting the viscosity of the matrix 22 and the surface tension of the interaction between the matrix 22 and the nanostrands 24, by comparison with the stiffness of the nanostrands 24. If the nanostrands 24 are not sufficiently stiff, they may be drawn apart from each other by the viscosity and surface tension effects of the matrix 22, thereby decreasing the electrical conductivity of the resulting composite material 20. The average diameter 28 may be optimized by providing an average diameter 28 just large enough to ensure that the stiffness of the nanostrands 24 is sufficient to resist these fluid and surface effects. Use of a larger diameter results in positioning of the nanostrands 24 further from each other (due to their size), thereby limiting the number of available conductive pathways.

Smaller diameter nanostrands 24 may also be used by applying additives to alter the viscosity or surface tension properties of the matrix 22 and/or the surface properties of the nanostrands 24. Surfactants may be used to wet the nanostrands 24, thereby decreasing the surface tension of the interface between the matrix 22 and the nanostrands. Furthermore, additives may be included in the matrix 22 to decrease the viscosity of the matrix.

As used herein, the term “metallic nanostrand” includes a variety of structures made wholly or mostly of one or more metals. The term “metal” excludes carbon because, although carbon may be considered a metal in some fields, carbon generally lacks the electrical conductivity to enable its efficient use in the present invention without the addition of a more conductive metal.

The composite material 20 may be made in a wide variety of ways, some of which will be set forth below in connection with FIGS. 6 and 7. According to one manufacturing method, the matrix 22 may be disposed in a viscous (i.e., flowable) form, and the nanostrands 24 may be mixed into the matrix 22. The matrix 22 may then be molded or otherwise disposed in a desired shape and permitted to cure to form the composite material 20. The polymer matrix may also be introduced by other techniques such as monomer in-situ polymerization and plasma polymerization.

If the matrix 22 is constructed of a ceramic material, known methods for ceramic matrix composite manufacturing may be applied. For example, chemical vapor deposition (CVD) techniques may be used in conjunction with, for example, carbides and/or silicon based materials to provide ceramic composites with the nanostrands 24.

In addition to electrical conductivity, the nanostrands 24 may provide additional properties such as mechanical strength and thermal conductivity. However, it may be desirable to further enhance such properties through the addition of larger fibers in conjunction with the nanostrands 24. This concept will be further shown and described in connection with FIG. 2.

Referring to FIG. 2, a perspective view illustrates an article 40 formed of a composite material 50 according to another embodiment of the invention. As shown in the inset, the composite material 50 has a nonmetallic matrix 52, or matrix 52, in which a plurality of metallic nanostrands 54, or nanostrands 54, and a plurality of fibers 56 are disposed. The nanostrands 54 have an average diameter 28 and average length 30, as described in conjunction with FIG. 1. Furthermore, the fibers 56 have an average diameter 58 and an average length 60. The average diameter 58 of the fibers 56 is much larger than the average diameter 28 of the nanostrands 54. Furthermore, the average length 60 of the fibers 56 may be much larger than the average length 30 of the nanostrands 54.

The nanostrands 54 may be configured in a manner similar to the nanostrands 24 of FIG. 1. Alternatively, the nanostrands 54 may be adapted to cooperate with the fibers 56. The nanostrands 54 are distributed about and between the fibers 56 in such a manner that the nanostrands 54 bridge the gaps between the fibers 56 to facilitate conveyance of electric current through the composite material 50. If these gaps are short, the nanostrands 54 may have comparatively small diameters, because surface tension and viscosity effects are less significant when the nanostrands 54 are simply bridging a short distance. Accordingly, the average diameter 58 may be comparatively small, for example, on the order of fifty nanometers.

The fibers 56 may be constructed of a plurality of electrically conductive materials such as nickel, iron, cobalt, chromium, molybdenum, and other metals. Alternatively, the fibers 56 may be made of a metal coated carbon fiber or the like. The fibers 56 may also be in the form of platelets. The fibers 56 and the nanostrands 54 may cooperate to synergistically improve the electrical conductivity of the composite material 50. “Synergistic improvement” refers to a combination that provides a higher electrical conductivity with a given volumetric concentration than the same volumetric concentration of either of the component parts alone.

For example, it has been observed that adding ten percent of a chopped metal-coated carbon fiber to a polymer matrix provided a volume resistivity of about one hundred ohm-cm. Using four percent of a particular nanostrand provided a similar volume resistivity. However, adding five percent of the chopped fiber and two percent of the nanostrands provided a volume resistivity of about ten ohm-cm, thereby providing a tenfold improvement. Using ten percent of the chopped fiber with four percent of the nanostrands yielded a volume resistivity of one ohm-cm or less, a one-hundred fold improvement. Thus, the nanostrands 54 and the fibers 56 interact synergistically to enhance the electrical conductivity of the composite material 50.

Similar effects may be obtained with continuous fiber composites. Such composites may already exhibit longitudinal conductivity in a direction parallel to the continuous fibers. However, nanostrands may be added either in a random orientation or in an orientation generally perpendicular to the continuous fibers to enhance the conductivity perpendicular to the fibers.

Due to such synergistic effects, the volumetric concentration of nanostrands included in the composite 50 may be much lower than that of the composite 20. For example, a two percent volumetric concentration of the nanostrands 54 may be quite sufficient to provide an enormous boost to the electrical conductivity of the composite material 50.

The fibers 56 may be selected simply for the purpose of optimizing electrical conductivity. Alternatively, the fibers 56 may be selected to provide other properties such as mechanical strength, rigidity, thermal conductivity, and the like. The fibers 56 may cooperate with the nanostrands 54 to provide enhanced electrical conductivity while being specifically selected to provide such other properties. Thus, selection of additives for enhancement of electrical conductivity may be at least partially decoupled from selection of additives for enhancement of such other properties. This enables separate selection of the desired volumetric concentrations of the nanostrands 54 and the fibers 56 to obtain the desired properties of the composite material 50.

The nanostrands 54 and the fibers 56 may be added to the matrix 22 in a manner similar to that described in connection with FIG. 1. If the fibers 56 are chopped fibers, they may be mixed into the matrix 22 along with the nanostrands 24. However, if the fibers 56 are continuous, they may be impregnated with the matrix 22 after mixing the nanostrands 24 into the matrix 22.

Generally, in the case of a composite with continuous fibers, the nanostrands act primarily to create conductivity throughout the otherwise non conducting matrix and to act as dispersed electrical collectors and direct that electrical current to the fibers. The fibers act also somewhat as electrical collectors, but furthermore act as very long conductive paths to dissipate the current to other areas of, or out of, the composite.

The nanostrands 24 of the composite material 20 of FIG. 1, as well as the nanostrands 54 and the fibers 56 of the composite material 50 of FIG. 2, are generally random in orientation. Thus, electrical conductivity may be expected to be substantially equal in all directions. In some applications, it may be desirable to maximize electrical conductivity along one selected direction. One method for obtaining such directional electrical conductivity will be shown and described in connection with FIG. 3, as follows.

Referring to FIG. 3, a perspective view illustrates an article 70 formed of a composite material 80 according to another alternative embodiment of the invention. The composite material 80 may contain a nonmetallic matrix 52, a plurality of nanostrands 54, and a plurality of fibers 56 like those of the composite material 50 of FIG. 2. Prior to curing, setting, or cooling of the matrix 52, the nanostrands 54 and the fibers 56 may be exposed to magnetic flux.

More precisely, a magnet 90 may be disposed proximate the composite material 80 with the matrix 52 in the viscous phase. The magnet 90 may be a permanent magnet, an electromagnet, a superconductive electromagnet, or the like. The magnet 90 has a positive pole 92 and a negative pole 94, which are shown having a longitudinal orientation with respect to each other. The magnet 90 produces magnetic flux 96 that passes around the magnet 90 between the positive and negative poles 92, 94.

The magnet 90 is positioned adjacent to the composite material 80 such that a portion of the magnetic flux 96 passes through the composite material 80 in the longitudinal direction 12. The magnetic flux 96 causes the nanostrands 54 and the fibers 56 to rotate into general alignment with the longitudinal direction 12, as illustrated. The nanostrands 54 bridge gaps between the fibers 56, as in the random orientation of FIG. 2. However, orientation of the nanostrands 54 and the fibers 56 in a common direction generally multiplies the number of electrical conduction pathways available to convey current in the longitudinal direction 12.

Thus, the electrical conductivity of the composite material 80 is greatly increased along the longitudinal direction 12, and commensurately reduced in the lateral and transverse directions 14, 16. However, in cases where the nanostrands 54 exhibit a lower aspect ratio and a higher amount of branching, the magnetic alignment will tend to “square up” the ordered branched structure and provide enhanced conductivity in all directions.

Consequently, magnetic orientation of nanostrands and/or fibers within a composite can be advantageous when it is desirable to obtain high electrical conductivity along a known direction. Such alignment of the magnetic material will also enhance the directional magnetic properties of the material by decreasing the material's magnetic reluctance. Such directional alignment may be useful for providing electrically or magnetically oriented ink for security purposes, screen printed circuitry, and the like. Magnetic alignment may even be reversibly applied to provide a digital memory module such as a magnetic data storage module, a sensor, a magnetically activated switch, or the like. Furthermore, the aligned magnetic nanostrands may act to polarize an electromagnetic wave, thus providing unique electro-magneto-optical properties.

The magnet 90 could easily be reoriented to align the nanostrands 54 and fibers 56 along the lateral direction 14 or the transverse direction 16, or along an oblique direction. Magnets with different polar configurations may alternatively be used to provide magnetic flux. If desired, an electromagnet (not shown) with a simple coil configuration may be disposed around the composite material 80. Upon activation, the coil produces magnetic flux through its center in a direction perpendicular to the coils, and thus, through the composite material 80.

The nanostrands 54 and the fibers 56 may be configured in a manner that provides relatively easy realignment. More specifically, the nanostrands 54 may have a certain minimum size, which is selected with reference to the viscosity and/or surface tension effects provided by the matrix 52. A more viscous matrix 52 that provides a higher resistance against motion of the nanostrands 54 requires the use of larger nanostrands 54 because more magnetic force is required to rotate the nanostrands 54. The strength of the magnet 90 may be increased to help overcome the viscosity and surface tension effects of the matrix 52. Longer fibers 56 and nanostrands 54 may also be more difficult to reorient than shorter ones, and may require compensation in terms of the strength of the magnet 90 or the viscosity and/or surface tension effects of the matrix 52.

These magnetic alignment effects may be applied to either nanostrands as a single additive, or applied to systems previously described that include a mixture of nanostrands and discontinuous fibers. The nanostrands 54 and the fibers 56 need not both be reoriented by the magnet 90. Rather, if desired, the size and aspect ratio of the nanostrands 54 and the length of the fibers 56 may be chosen in accordance with the chemistry, viscosity and surface tension of the matrix and the strength and direction of the magnetic fields to selectively orient (or not orient) only the nanostrands 54 or only the fibers 56.

For example, the nanostrands 54 may deliberately be made too small for realignment so that the nanostrands 54 remain generally randomly oriented. Alternatively, the fibers 56 may be constructed of a nonmagnetic material so that only the nanostrands 54 are reoriented. Furthermore, magnetic realignment may be practiced with a material like the composite material 20 of FIG. 1, in which only the nanostrands 24 are present. FIG. 3 illustrates the presence of the fibers 56 and nanostrands 54 simply by way of example.

As another alternative, magnetic realignment may be used to reorient nanostrands 54 disposed with fibers in a continuous fiber composite material. Although the continuous fibers (not shown) may not be reoriented, the nanostrands 54 can be magnetically oriented parallel to the continuous fibers to enhance electrical conductivity along the direction of the fibers. Alternatively, the nanostrands 54 may be magnetically oriented perpendicular to the continuous fibers to enhance electrical conductivity in directions nonparallel to the continuous fibers.

Some conductive composites according to the invention may provide variable electrical conductivity. Such composite materials may be used in sensors or other applications. One example of a sensor incorporating a composite material according to the invention will be shown and described in connection with FIG. 4.

Referring to FIG. 4, a pressure sensor 100 is illustrated. As shown, the pressure sensor 100 includes the article 10 of FIG. 1, which is made of a composite material 20. The composite material 20 includes a matrix 22 and a plurality of nanostrands 24, as illustrated in FIG. 1. In the alternative, continuous or chopped fibers 56 may be included as in the composite material 50 of FIG. 2, and the nanostrands 22 and/or fibers 56 may or may not be magnetically oriented in the manner indicated in FIG. 3.

The matrix 22 may be an elastomer such as silicone rubber. It has been found that, when disposed in an elastomeric matrix, the nanostrands 24 may provide an electrical conductivity that varies in proportion to deformation of the elastomer. More precisely, either tensile or compressive strain of the elastomer may tend to increase the electrical conductivity of the composite.

In one test, a silicone elastomer was loaded with an eight percent volumetric concentration of nanostrands to form a composite material. In an undeformed state, the volume resistivity of the composite structure was about fifty ohm-cm. When the composite structure was stretched to one-hundred and twenty percent of its original length or compressed to half its original thickness, the volume resistivity dropped to two-tenths of an ohm-cm. This principle may be used to enable use of metallic nanostrand-based composite materials in sensors.

In the implementation of FIG. 4, the article 10 is attached to a backing member 102, which may be constructed of a stiff, relatively nonconductive material. The article 10 is connected as part of an electric circuit 104 that includes a voltage source 106 and a current sensor 108 disposed in series with the voltage source 106 and the article 10.

When pressure is applied to the article 10 in the transverse direction 16, as indicated by the arrow 110, the article 10 is compressed transversely against the backing member 102. Simultaneously, the voltage source 106 induces electric current to flow through the article 10 in the longitudinal direction 12. As the article 10 is compressed, its electrical conductivity increases. Hence, the current flowing through the article 10 increases (assuming the voltage of the voltage source 106 is constant). The current sensor 108 reads the current during deformation.

Comparison of the current level under deformation with the current flowing through the article 10 in the undeformed state indicates the magnitude of the deformation. The magnitude of the deformation is proportional to the magnitude of the force indicated by the arrow 110. Thus, the pressure sensor 100 may act to measure a simple, point load, or a pressure distributed over the surface of the composite material 20. The pressure sensor 100 is simplified in form; other backing members, seals, and the like may be utilized to enhance the accuracy of the pressure sensor 100. If desired, such structures may be used to limit deformation of the composite material 20 to a single direction, such as the transverse direction 16.

Such a sensor may readily be used as a structural strain gage, an integral end effect tactile sensor for robotics or bionics, or the like. Furthermore, such a sensor may be adapted to measure a wide variety of electrical or magnetic properties as a function of mechanical forces in any direction. Such a sensor may be adapted to provide a temperature sensor by, for example, selecting a matrix 22 having a comparatively high coefficient of thermal expansion. The thermal expansion or contraction of the composite material 20 causes a corresponding change in the electrical conductivity of the composite material. The change in electrical conductivity can be measured in the manner indicated in FIG. 4 to measure the temperature change. In the alternative to elastomers, phase changing polymers or ceramics/slats may be possibly be used to provide the matrix 22.

Furthermore, such composite structures may potentially be adapted to change their size or shape as a function of applied electric current or magnetic fields. Thus, nanostrand-based composite materials may possibly be usable as muscles or motors as well as sensors.

In certain applications, it may be desirable to have an article that is generally formed of a nonconductive material, and to make that material conductive without altering the interior structure of the material. Such a procedure is useful in modifying existing equipment to provide conductive surfacing, as in the case of electromagnetic shielding. Furthermore, such a procedure is useful for articles that cannot reasonably be constructed of a solid composite material. One embodiment of a composite material that can be applied to a surface will be shown and described in connection with FIG. 5.

Referring to FIG. 5, a perspective view illustrates an article 120 to which composite materials according to the invention are applied to provide electrical conductivity. As shown, the article 120 includes a body 122 having a surface 124, the electrical conductivity of which is to be enhanced. An electrically conducive mixture 130 has been applied to the surface 124 to enhance its electrical conductivity. The use of such an electrically conductive mixture 130 has a number of applications, including electro-static discharge, electromagnetic radiation shielding and absorption, lightning strike protection, and stun gun or microwave mitigation.

The electrically conductive mixture 130 is a composite material, which may be similar to any of the composite materials 20, 50, 80 disclosed in connection with FIGS. 1, 2, and 3. Hence, the electrically conductive mixture 130 has a matrix with nanostrands, with optional larger fibers and optional magnetic alignment or sensor capability of the nanostrands and/or fibers. The matrix, nanostrands, and fibers have been illustrated in connection with previous embodiments, and hence are not shown in FIG. 5.

The matrix of the electrically conductive mixture 130 may advantageously be a polymer of a type commonly used for paints, such as an epoxy, acrylic, water based paint, urethane, or lacquers. The nanostrands, and optionally, larger fibers, may be mixed into the matrix in a viscous stage as described previously to form the electrically conductive mixture 130. The electrically conductive mixture 130 may then be applied to the surface 124 in a manner similar to that of ordinary paints. For example, the electrically conductive mixture 130 may be mechanically applied through the use of brushes, rollers, spray nozzles, or the like. Alternatively, the electrically conductive mixture 130 may be deposited via chemical or other methods.

A number of methods may be used to produce the composite materials of the present invention. Known methods for composite manufacture may be applied to nanostrand-based composites, as indicated previously. Other methods may alternatively be used to obtain conductivity enhancements or to facilitate manufacturing. Two exemplary manufacturing methods will be shown and described in connection with FIGS. 6 and 7, as follows.

Referring to FIG. 6, a flowchart diagram illustrates a method 140 for manufacturing a composite article according to one embodiment of the invention. The method 140 may be used to manufacture a composite article with a certain desired shape.

According to the method 140, a nanostrand porous sponge, or “blank,” is formed 142, for example, through the use of the methods described in U.S. Pat. No. 5,130,204. A “blank” is simply a volume of nanostrands having an arbitrary shape (i.e., the shape in which they were manufactured, which may be a sheet, a brick, a biscuit, or the like). A portion of the nanostrands are removed 144 from the blank to provide a preform with the desired shape of the composite product. A “preform” is a porous mass of interconnected nanostrands with a deliberately selected shape. Hence, unlike the blank, the preform has a shape that may be nonplanar (i.e., not sheet-like) and is not determined simply by the process used to form the nanostrands, although the nanostrands may be advantageously manufactured in a shape near that of the desired blank.

The blank may be mechanically cut, chemically removed, cut via lasers or electric discharge, or shaped in some other known manner to form the preform. Compaction of the blank may advantageously be avoided during removal of the portion of the nanostrands to maintain the porosity of the blank. The preform may then have a truly continuous three-dimensional lattice of nanostructured conductive material with a porosity in excess of ninety-nine percent. Some measured compaction may be used if a lower porosity is desirable, or if needed to achieve a particular finished complex geometry. Such a preform may be used without a matrix in applications such as filtering, catalysts, batteries, and gas absorption and/or storage.

Once the preform has been obtained, the nonmetallic material of the matrix is directed 146 into the preform. This may be accomplished by exposing the preform to the matrix material in the viscous phase, monomer phase, plasma phase or vapor phase. The matrix material may be pressurized and injected to facilitate relatively complete filling of the preform. The matrix is then allowed to cure, set or cool 148 to solidify the matrix, thereby forming the composite article with the desired shape. The composite material produced may have a structure similar to that of the composite material 20 of FIG. 1. The article may then be ready for direct application of subsequent final finishing or secondary molding to the desired shape.

According to alternative methods, larger fibers may be added into the blank during production of the nanostrands so that the blank is a lattice containing both the nanostrands and the larger fibers. Thus, the composite article will have the larger fibers, and may have a structure similar to that of the composite material 50 of FIG. 2.

Referring to FIG. 7, a flowchart diagram illustrates a method 150 for manufacturing a composite article according to another embodiment of the invention. Like the method 140, the method 150 may be used to manufacture a composite article with a certain desired shape.

According to the method 150, a nanostrand powder is first formed 152. This may be accomplished by forming the nanostrands initially as a powder, or by breaking up a nanostrand blank and screening the fragments to provide a powder. A solution of carrier fluid and suspension agent and surfactant(s) is then directed 154 into the nanostrands. Pretreatment of the nanostrands with appropriate surfactants may be advantageous. This nanostrand/fluid mixture is then disposed 156 in the desired shape, for example, by pouring the mixture into a mold of desired shape and size, with allowances made in the design for shrinkage.

The suspension agent helps to cause the nanostrands to adhere to one another. The suspension agent and the liquid may be removed 158 from the nanostrands via a process such as solvation or evaporation. Some of the suspension agent, or a related surfactant or adherent, may be permitted to remain in the nanostrands to maintain the attachment of the nanostrands to each other. Alternatively, slight thermal sintering may be applied to the nanostrands to keep the nanostrands attached together.

After the fluid and the suspension agent has been removed, the resulting structure is similar to the preform described above, in connection with the method 140 of FIG. 6. The nanostrands form a three-dimensional lattice having the desired shape. However, the resulting lattice may have a slightly lower porosity, which may range from about ninety-two percent to about ninety-seven percent.

The nonmetallic material of the matrix may then be directed 160 into the nanostrands in a manner similar to that described in connection with the previous embodiment. The matrix material may then be cured, set, or cooled 162 to form the composite article with the desired shape.

This method provides the advantage that any desired porous nanostrand shape can be created from a base material of bulk screened nanostrands. Thus, composite articles may be created with a larger variety of shapes and sizes. The screened nanostrands may also be easily shipped to a manufacturing site and used with little scrap.

The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1-21. (canceled)
 22. A method for manufacturing a composite material capable of conducting electricity, the method comprising: forming a plurality of metallic nanostrands having an average diameter less than about four microns and an average aspect ratio greater than about ten-to-one; providing a plurality of fibers having an average diameter greater than about four microns; and distributing the metallic nanostrands and the fibers substantially throughout a matrix formed substantially of a nonmetallic material.
 23. The method of claim 22, wherein distributing the metallic nanostrands substantially throughout the matrix comprises providing a total volumetric concentration of the metallic nanostrands and the fibers within the matrix sufficient to provide an electrical conductivity of the composite material that is at least ten times an electrical conductivity of the nonmetallic material alone.
 24. The method of claim 23, wherein distributing the metallic nanostrands substantially throughout the matrix comprises providing a volumetric concentration of the metallic nanostrands ranging from about one-half of a percent to about twenty percent.
 25. The method of claim 22, further comprising selecting the fibers in such a manner that the fibers cooperate with the metallic nanostrands to synergistically improve an electrical conductivity of the composite material.
 26. The method of claim 22, further comprising selecting the fibers in such a manner that the fibers enhance a mechanical strength of the composite material.
 27. The method of claim 22, wherein forming the metallic nanostrands comprises constructing the metallic nanostrands substantially of nickel.
 28. The method of claim 22, wherein distributing the metallic nanostrands substantially throughout the matrix comprises distributing the metallic nanostrands substantially throughout a nonconductive material selected from the group consisting of elastomers and ceramics.
 29. The method of claim 28, wherein the nonconductive material comprises an elastomer, wherein distributing the metallic nanostrands substantially throughout the matrix comprises providing an electrical conductivity of the composite material that varies generally in proportion to a magnitude of deformation of the elastomer.
 30. The method of claim 22, further comprising applying magnetic flux to the metallic nanostrands and the matrix to orient the metallic nanostrands generally parallel to each other to enhance an electrical conductivity of the composite material along one direction.
 31. The method of claim 30, further comprising applying magnetic flux to orient the fibers generally parallel to the metallic nanostrands.
 32. The method of claim 22, wherein distributing the metallic nanostrands substantially throughout the matrix comprises forming an electrically conductive mixture capable of being applied to coat at least a portion of a surface of a body such that the metallic nanostrands act to convey electric current through the matrix to enhance electrical conductivity of the surface.
 33. The method of claim 22, wherein forming the metallic nanostrands comprises utilizing a process selected to provide a comparatively high degree of branching of the metallic nanostrands.
 34. The method of claim 22, further comprising applying a surfactant to the nanostrands to reduce surface tension of the matrix against the nanostrands.
 35. The method of claim 22, further comprising applying an additive to the matrix to reduce a viscosity of the matrix.
 36. The method of claim 22, further comprising disposing the matrix and the metallic nanostrands in a shape through which electricity is to be conducted.
 37. The method of claim 36, wherein disposing the metallic nanostrands in a shape through which electricity is to be conducted comprises creating a preform of the metallic nanostrands, the preform having the shape, wherein distributing the metallic nanostrands substantially throughout the matrix comprises directing the nonmetallic material into the preform such that the nonmetallic material substantially fills interstices between the metallic nanostrands.
 38. The method of claim 36, wherein disposing the metallic nanostrands in a shape through which electricity is to be conducted comprises: breaking up the metallic nanostrands; mixing the metallic nanostrands with a suspension agent such that the metallic nanostrands and the suspension agent receive the shape; and removing the suspension agent; wherein distributing the metallic nanostrands substantially throughout the matrix comprises directing the nonmetallic material into the metallic nanostrands such that the nonmetallic material substantially fills in interstices between the metallic nanostrands.
 39. The method of claim 22, further comprising curing the matrix.
 40. A method for manufacturing a composite material, the composite material having enhanced electrical conductivity along one direction, the method comprising: forming a plurality of metallic nanostrands having an average diameter less than about four microns; distributing the metallic nanostrands substantially throughout a matrix formed substantially of a nonmetallic material; and applying magnetic flux to the metallic nanostrands to induce reorientation of the metallic nanostrands toward the direction.
 41. The method of claim 40, wherein applying magnetic flux to the metallic nanostrands comprises disposing at least one permanent magnet proximate the metallic nanostrands
 42. The method of claim 40, wherein applying magnetic flux to the metallic nanostrands comprises: disposing at least one electromagnet proximate the metallic nanostrands; and activating the electromagnet.
 43. The method of claim 40, wherein distributing the metallic nanostrands substantially throughout the matrix comprises distributing the metallic nanostrands substantially throughout a polymer, wherein forming the metallic nanostrands comprises constructing the metallic nanostrands substantially of nickel.
 44. The method of claim 43, wherein the polymer comprises a viscosity and a surface tension, wherein the viscosity, the surface tension, and the average diameter of the metallic nanostrands are selected to permit rotation of the nanostrands within the matrix in response to application of the magnetic flux.
 45. The method of claim 40, further comprising creating a preform of the metallic nanostrands, the preform having a desired shape, wherein distributing the metallic nanostrands substantially throughout the matrix comprises directing the nonmetallic material into the preform such that the nonmetallic material substantially fills in interstices between the metallic nanostrands.
 46. A method for manufacturing a composite material, the composite material having enhanced electrical conductivity along one direction, the method comprising: forming a plurality of metallic nanostrands having an average diameter less than about four microns; and distributing the metallic nanostrands substantially throughout a matrix formed substantially of a nonmetallic material selected from the group consisting of elastomers and ceramics.
 47. The method of claim 46, wherein distributing the metallic nanostrands substantially throughout the matrix comprises distributing the metallic nanostrands substantially throughout a nonconductive material selected from the group consisting of elastomers and ceramics.
 48. A method for measuring deformation of a nonconductive material, the method comprising: forming a plurality of metallic nanostrands having an average diameter less than about four microns; distributing the metallic nanostrands substantially throughout a matrix formed of the nonconductive material to form a composite material comprising the metallic nanostrands and the nonconductive material; applying the deformation to the nonconductive material; and measuring electrical conductivity of the deformed composite material to determine a magnitude of the deformation.
 49. The method of claim 48, further comprising measuring the electrical conductivity of the composite material prior to application of the deformation, wherein determining the magnitude of the deformation comprises comparing the electrical conductivity in the deformed state with the electrical conductivity prior to application of the deformation.
 50. The method of claim 48, wherein the deformation comprises at least one of the group consisting of tension and compression, each of which causes the electrical conductivity to increase.
 51. The method of claim 48, wherein the nonconductive material comprises an elastomer.
 52. The method of claim 48, wherein forming the metallic nanostrands comprises constructing the metallic nanostrands substantially of nickel.
 53. The method of claim 48, wherein the composite material is a component of a pressure sensor.
 54. The method of claim 48, wherein the composite material is a component of a temperature sensor that senses temperature by sensing thermal expansion and contraction of the composite material.
 55. A method for manufacturing a composite article having a nonplanar shape, the method comprising: forming a blank comprising a plurality of metallic nanostrands having an average diameter less than about four microns removing a portion of the metallic nanostrands from the blank to provide a preform having the nonplanar shape; and directing a nonmetallic material into the preform such that the nonmetallic material substantially fills interstices between the metallic nanostrands to form a matrix having the nonplanar shape.
 56. The method of claim 55, wherein removing a portion of the metallic nanostrands from the blank comprises cutting the blank.
 57. The method of claim 55, wherein the preform is over ninety-five percent porous, wherein directing the nonmetallic material into the preform comprises disposing the nonmetallic material in a form selected from the group consisting of a viscous phase, a monomer phase, and a vapor phase of the nonmetallic material.
 58. A method for manufacturing a composite article having a shape, the method comprising: forming metallic nanostrands in powder form; mixing the metallic nanostrands with a suspension agent such that the metallic nanostrands and the suspension agent receive the shape; removing the suspension agent; and directing the nonmetallic material into the metallic nanostrands such that the nonmetallic material substantially fills in interstices between the metallic nanostrands to form a matrix having the shape.
 59. The method of claim 58, wherein mixing the metallic nanostrands with the suspension agent comprises mixing the metallic nanostrands with a fluid mixture containing the suspension agent, wherein the metallic nanostrands are at least ninety percent porous after removal of the suspension agent.
 60. The method of claim 58, wherein removing the suspension agent comprises using a method selected from the group consisting of evaporation and solvation. 